Method for forming components using additive manufacturing and re-melt
A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.
1. A method of manufacturing a component, comprising:
additively manufacturing the component with a metal material;
additively manufacturing a core at least partially within the component;
at least partially encasing the component and the core within a shell;
melting the additively manufactured component;
solidifying the metal material of the additively manufactured component to form a directionally solidified microstructure within the component; and
removing the shell and the core to reveal the component.
2. The method of claim 1 , wherein the step of solidifying the metal material includes directionally solidifying the material to have a single crystal microstructure.
3. The method of claim 1 , wherein the step of solidifying the metal material includes directionally solidifying the material to have a columnar grain microstructure.
4. The method as recited in claim 1 , wherein the metal material is a powder.
5. The method as recited in claim 1 , wherein the core at least partially defines at least one internal passageway within the component.
6. The method as recited in claim 5 , further comprising concurrently additively manufacturing the component and the core within the component.
7. The method as recited in claim 5 , wherein the core at least partially defines microchannels within the component.
8. The method as recited in claim 7 , wherein the microchannels are additively manufactured of a refractory material and the internal passageways are manufactured of a ceramic material.
9. The method as recited in claim 8 , wherein the additive manufacturing is performed by a multi-powder bed system.
10. The method as recited in claim 1 , further comprising applying a wax material at least partially onto the component.
11. The method as recited in claim 10 , further comprising melting the wax material prior to melting the additively manufactured component.
12. The method as recited in claim 10 , further comprising applying the wax material to an airfoil portion of the component.